Upper structure of vehicle and method for manufacturing upper structure of vehicle

Abstract

To provide an upper structure of a vehicle that can reduce vibrational energy that is transmitted to a top ceiling, without weakening rigidity of the top ceiling.SOLUTION: A vehicle is provided with a roof panel, a rear header 19 and a top ceiling 17. The rear header 19 is arranged inside a vehicle interior with respect to the roof panel and is extended in a vehicle width direction. The top ceiling 17 is arranged inside the vehicle interior with respect to the rear header 19 to cover the roof panel from the inside of the vehicle interior. The top ceiling 17 is fixed to the rear header 19 by a pair of clips 21. The pair of clips 21 fix the top ceiling 17 to the rear header 19, at a position where dimensions in the vehicle width direction between center lines extending in a vehicle longitudinal direction and the clips are equal to each other at an intermediate position in the vehicle width direction of the top ceiling 17, and at which a distance between the pair of clips 21 is equal to 35% or less or 80% or more of a width in the vehicle width direction of a rear end 17a of the top ceiling 17.SELECTED DRAWING: Figure 3

Description

[Technical Field]

[0001] The present invention relates to a vehicle upper structure, and more particularly to a vibration suppression structure for a top ceiling in a vehicle. [Background technology]

[0002] To suppress noise inside the vehicle, the inventors conducted extensive research into the mechanism of vibration transmission by analyzing the flow of vibration energy between units based on the modal characteristics of each unit that makes up the vehicle. As a result, it was discovered that with regard to the vibration of the top ceiling that covers the roof panel from the inside of the vehicle, the coupling of displacement due to the eigenmode of the top ceiling, which is a flexible structure, and displacement due to forced vibration from the car body, which is a rigid structure, is the factor that transmits vibration energy to the top ceiling.

[0003] Generally, when fastening a top ceiling to a vehicle body, a rigid connection structure using fastening members and brackets is known. For example, in the structure described in Patent Document 1, as shown in Fig. 11, a top ceiling UTR is fixed via a bracket 101 to an inner panel 100a of a roof side rail 100, which is a vehicle body component and extends in the vehicle fore-and-aft direction (a direction perpendicular to the plane of Fig. 11). The top ceiling UTR is firmly fixed to the bracket 101 by a fastening member 102, and the bracket 101 is further firmly fixed to the inner panel 100a by a fastening member 103. As a result, the top ceiling UTR is firmly fixed to the vehicle body by the bracket 101 and the fastening members 102 and 103. Furthermore, by being fixed to the inner panel 100a, the top ceiling UTR partially overlaps the end of the roof trim RT.

[0004] However, with the rigid connection structure described above, the vibration energy generated in the car body is transmitted directly to the flexible top ceiling UTR via the rigid connection structure of bracket 101 and fastening members 102 and 103. Therefore, in order to suppress the transmission of vibration energy, it is necessary to take measures to block the displacement component caused by forced vibration.

[0005] Therefore, as a structure intended to block displacement components due to forced vibration, for example, in the structure described in Patent Document 2, as shown in Fig. 12, in which a top sealing 202 is fixed to a front header 201, which is a vehicle body component and extends in the vehicle width direction (direction perpendicular to the plane of Fig. 12), using fastening members 203, a technology is known for reducing vibration by weakening the rigidity of a peripheral portion 202a of an insertion hole 202b in the top sealing 202, into which the fastening member 203 is inserted. Specifically, the plate thickness of the peripheral portion 202a of the insertion hole 202b in the top sealing 202 is smaller than the plate thickness of other portions, so the rigidity of the peripheral portion 202a is partially weakened. [Prior art documents] [Patent documents]

[0006] [Patent Document 1] Japanese Patent Application Laid-Open No. 2008-114797 [Patent Document 2] Japanese Patent Publication No. 2023-090245 Summary of the Invention [Problem to be solved by the invention]

[0007] However, in the structure shown in Figure 12 above, the rigidity of the peripheral portion 202a of the fastening portion of the top sealing 202 is partially weakened, but since it is necessary to ensure the retention of the top sealing 202, it is difficult to significantly weaken the rigidity of the top sealing 202, and there is room for improvement.

[0008] The present invention has been made to solve the above-mentioned problems, and aims to provide a vehicle upper structure that can reduce the vibration energy transmitted to the top ceiling without weakening the rigidity of the top ceiling. [Means for solving the problem]

[0009] The vehicle upper structure of the present invention reduces the forced displacement component of the vibration energy transmitted from the vehicle body to the top sealing by fixing the top sealing to the deformation node of the rear header or its vicinity via fastening members. In other words, the upper structure of a vehicle of the present invention comprises a roof panel, a rear header extending in the vehicle width direction and fixed to the rear end of the roof panel, a top ceiling positioned on the inside of the vehicle compartment relative to the rear header and covering the roof panel from the inside of the vehicle compartment, and at least a pair of first fastening members that fix the top ceiling to the rear header, wherein the pair of first fastening members fix the top ceiling to the rear header at positions where their vehicle width dimensions are equal to the center line extending in the fore-and-aft direction of the vehicle at the vehicle width middle position of the top ceiling, and where the distance between the pair of first fastening members is 35% or less or 80% or more of the vehicle width width of the rear end of the top ceiling.

[0010] The displacement of the rear header is greatest at the position of the antinode of the deformation in the vibration mode of the rear header in the frequency range when road noise is generated. The antinode position of the rear header and its surrounding area are areas where the displacement is locally large. Research by the inventors has revealed that such areas of large displacement in the rear header are areas where there are two points that are equal in vehicle width direction dimension to the center line of the top ceiling and are separated by a distance of 37 to 78% of the vehicle width direction width of the rear end of the top ceiling.

[0011] Therefore, the present invention was created based on the idea that vibration of the top ceiling can be suppressed by arranging the fastening member at or near the node position, avoiding the above-mentioned antinode position and its surrounding area.

[0012] That is, as described above, the pair of first fastening members fasten the top ceiling to the rear header at positions where their vehicle widthwise dimensions are equal to the centerline extending in the vehicle's fore-and-aft direction at the vehicle widthwise center of the top ceiling, and where the distance between the pair of first fastening members is 35% or less or 80% or more of the vehicle width of the rear end of the top ceiling. This allows the top ceiling to be fixed by the fastening members at or near the deformation node position, i.e., the position where displacement is minimum, in the vibration mode of the rear header in the frequency range when road noise is generated. This suppresses the transmission of vibration energy to the top ceiling, thereby suppressing the transmission of road noise that is unpleasant to vehicle occupants. This achieves a vibration reduction effect of 2 dB or more in the top ceiling. As a result, it is possible to reduce the vibration energy transmitted to the top ceiling without weakening the rigidity of the top ceiling.

[0013] In the above-mentioned vehicle upper structure, it is preferable that the pair of first fastening members fix the top ceiling to the rear header at a position where the distance between the pair of first fastening members is 30% or less or 90% or more of the width of the rear end of the top ceiling in the vehicle width direction.

[0014] This configuration further reduces the transmission of vibration energy to the top ceiling, thereby further reducing the transmission of road noise that is unpleasant to vehicle occupants. Specifically, the top ceiling achieves a vibration reduction effect of 3 dB or more.

[0015] The above vehicle upper structure preferably further comprises a second fastening member that fastens the top ceiling to the rear header at a middle position of the top ceiling in the vehicle width direction.

[0016] The middle position of the top ceiling in the vehicle width direction is the position of the deformation node in the vibration mode of the rear header, so in addition to fixing it with the pair of first fastening members described above, by further fixing the top ceiling to the rear header at this middle position in the vehicle width direction with a second fastening member, it is possible to fix the top ceiling more stably with the pair of first and second fastening members while suppressing the vibration of the top ceiling.

[0017] In the above vehicle upper structure, the pair of first fastening members are preferably disposed at a middle position in the vehicle width direction of the top ceiling.

[0018] In this configuration, each of the pair of first fastening members is positioned at a transversely intermediate position of the top ceiling, which is the position of a deformation node in the vibration mode of the rear header. In other words, the distance between the pair of first fastening members in the transverse direction of the vehicle is zero, and the ratio of the distance to the width of the rear end of the top ceiling is 0%. By positioning the pair of first fastening members at transversely intermediate positions in this manner, it is possible to further suppress the transmission of vibration energy to the top ceiling and further suppress the transmission of road noise that is unpleasant to vehicle occupants.

[0019] The manufacturing method of the vehicle upper structure of the present invention, which is suitable for the above-mentioned vehicle upper structure, is characterized by including: a preparation process of fixing the pair of first fastening members to the vehicle width intermediate position of the top sealing and fixing a pair of temporary fastening members to both end portions in the vehicle width direction; a temporary fastening process of temporarily fastening both end portions of the top sealing to the rear header by temporarily fastening the pair of temporary fastening members to the rear header; a work process of assembling the vehicle after the temporary fastening process; and a final fastening process of fixing the top sealing to the rear header at the vehicle width intermediate position by the pair of fastening members after the work process by fixing the pair of fastening members to the rear header and detaching the pair of temporary fastening members from the rear header.

[0020] In this manufacturing method, in a preparation step, a pair of first fastening members are fixed at a vehicle widthwise intermediate position, and a pair of temporary fastening members are fixed to both ends in the vehicle width direction. Then, before the top sealing is permanently fixed to the rear header with the pair of first fastening members, in a temporary fastening step, the pair of temporary fastening members are temporarily fastened to the rear header in advance, thereby temporarily fastening both ends of the top sealing in the vehicle width direction to the rear header in advance. This makes it possible to maintain assembly accuracy when assembling the top sealing in the subsequent permanent fastening step. Therefore, even if various work processes for vehicle assembly are performed before the permanent fastening step, the top sealing is supported at both ends by the pair of temporary fastening members, so that displacement and deformation of the top sealing can be prevented. Note that the work process also includes a waiting step.

[0021] After the top sealing is temporarily fixed with the pair of temporary fastening members, the pair of fastening members are fixed to the rear header in the main fixing process, and the pair of temporary fastening members are then released from the rear header, thereby fixing the top sealing to the rear header with the pair of fastening members aligned in the fore-and-aft direction of the vehicle at a midpoint in the vehicle width direction. This makes it possible to accurately and reliably fix the top sealing to the midpoint in the vehicle width direction, which is the position of the node of deformation of the rear header, with the pair of first fastening members.

[0022] In the manufacturing method of the vehicle upper structure described above, it is preferable that in the preparation process, the top sealing is prepared so that the portion between the both ends of the vehicle width direction of the top sealing can be displaced between a first form curved downward and a second form curved upward by elastically deforming in the vertical direction, and that the top sealing has an alternative shape retention function that selectively retains either the first form or the second form, and in the temporary fixing process, the pair of temporary fixing members fixed to the both ends of the vehicle width direction of the top sealing are temporarily fixed to the rear header when the top sealing is in the first form, and in the main fixing process, the pair of first fastening members fixed to the intermediate position in the vehicle width direction of the top sealing are fixed to the rear header, and the portion between the both ends of the vehicle width direction of the top sealing is elastically deformed to transition from the first form to the second form, thereby lowering the both ends of the vehicle width direction and detaching the pair of temporary fixing members from the rear header.

[0023] In this feature, the pair of first fastening members and the pair of temporary fastening members are connected by the elastically deformable top sealing as described above, so that when the pair of first fastening members located at the vehicle widthwise intermediate position of the top sealing are fastened to the rear header in the main fastening process, the top sealing is elastically deformed to transition from the first configuration to the second configuration, thereby lowering both ends of the top sealing in the vehicle width direction and automatically detaching the pair of temporary fastening members from the rear header. Therefore, in the main fastening process, the pair of first fastening members can be automatically detached simply by fastening the pair of first fastening members, making it easier to install the top sealing. [Effects of the Invention]

[0024] According to the vehicle upper structure of the present invention, it is possible to reduce vibration energy transmitted to the top ceiling without weakening the rigidity of the top ceiling. [Brief explanation of the drawings]

[0025] [Figure 1]1 is a plan view showing an upper structure of a vehicle according to an embodiment of the present invention. [Figure 2] 1. FIG. 4 is an explanatory diagram showing the distance between two fixing points at which the top ceiling is fixed to the rear header by a pair of first fastening members relative to the overall width of the rear end of the top ceiling in the vehicle longitudinal direction. [Figure 3] 3 is a graph showing the relationship between the ratio of the length between a pair of first fastening members to the overall width of the rear end of the top ceiling in the vehicle longitudinal direction in FIG. 2 and the difference in equivalent radiant power (ERP) from a comparative example having a conventional structure. [Figure 4] 2 is a contour map showing, by shades of gray, the degree of displacement at each part of the rear header in the vehicle width direction when vibration is applied to the vehicle body, when the rear header in FIG. 1 is viewed from the rear of the vehicle. [Figure 5] 2 is a contour map showing, by shades of gray, the degree of displacement at each part of the rear header in the vehicle width direction when vibration is applied to the vehicle body, when the rear header in FIG. 1 is viewed from above the vehicle. [Figure 6] This is an explanatory diagram showing that, as one embodiment of the present invention, the two fixing points at which the top sealing is fixed to the rear header by the pair of first fastening members in Figure 1 are located sufficiently inside the position P1 of the two fixing points in the comparative example. [Figure 7] FIG. 10 is an explanatory diagram showing another embodiment of the present invention, in which the two fixing points at which the top sealing is fixed to the rear header by the pair of first fastening members in FIG. 1 are positioned side by side in the fore-and-aft direction of the vehicle at a midpoint in the vehicle width direction corresponding to the node positions. [Figure 8] As yet another embodiment of the present invention, this is an explanatory diagram showing that the two fixing points at which the top sealing is fixed to the rear header by the pair of first fastening members in Figure 1 are located sufficiently outside the position P1 of the two fixing points in the comparative example, and that the second fastening member is located at the fixing point position at the middle position in the vehicle width direction. [Figure 9]As an example of a suitable manufacturing method for manufacturing the upper structure of a vehicle in which the two fixing points of the top sealing in Figure 7 are aligned in the fore-and-aft direction of the vehicle at the midpoint in the vehicle width direction, this is an explanatory diagram that explains how, in a state in which the top sealing maintains its first form curved downward, the top sealing is temporarily fixed using a pair of temporary fixing members at both ends in the vehicle width direction in a temporary fixing process before the top sealing is permanently fixed using a pair of first fastening members at the midpoint in the vehicle width direction. [Figure 10] This is an explanatory diagram that explains that after the temporary fixing process in Figure 9, in the final fixing process, the top sealing is permanently fixed using a pair of first fastening members located at the middle position in the vehicle width direction, and the top sealing is elastically deformed and displaced into a second shape curved upward, automatically detaching the pair of temporary fixing members located at both ends in the vehicle width direction. [Figure 11] 1 is a cross-sectional view showing a conventional vehicle upper structure in which a top ceiling is firmly fixed to a roof side rail via a bracket. [Figure 12] FIG. 10 is a cross-sectional view showing another example of a conventional vehicle upper structure, in which the plate thickness of the periphery of a through hole in a top sealing into which a fastening member is inserted is thinned. DETAILED DESCRIPTION OF THE INVENTION

[0026] Hereinafter, embodiments of the present invention will be described with reference to the drawings. Note that the embodiments described below are merely illustrative of the present invention, and the present invention is not limited to the following embodiments except for the essential configuration.

[0027] The upper structure of a vehicle 1 according to this embodiment will be described with reference to the drawings. Note that Fig. 1 illustrates an extracted portion of the upper structure of the vehicle 1. Note that arrows Fr, Re, Ri, Le, Up, and Lo in the drawing indicate the front, rear, rightward, leftward, upward, and downward directions of the vehicle 1, respectively.

[0028] As shown in Fig. 1, the vehicle 1 includes a roof panel (not shown in Fig. 1), a pair of left and right front pillars 10, a pair of left and right center pillars 11, a pair of left and right roof side rails 12, a front header 13, a pair of left and right gussets 14, roof rains 15 and 16, a rear header (body frame member) 19, and a top ceiling 17. The roof panel is attached to the front header 13, the roof rains 15 and 16, and the rear header 19.

[0029] The front header 13 is joined to the front portion of the roof panel and is configured to extend in the vehicle width direction. Gussets 14 are joined to the left and right sides of the front header 13 and to the roof side rails 12. The roof rains 15, 16 are arranged rearward and spaced apart from the front header 13, and are also arranged spaced apart from each other in the front-to-rear direction.

[0030] The rear header 19 is a member that is disposed on the inner side of the vehicle cabin relative to the roof panel and that forms the framework of the vehicle body, extending in the vehicle width direction. The rear header 19 is joined to the rear portion of the roof panel.

[0031] The top ceiling 17 is an interior component that is disposed on the passenger compartment inner side of the front header 13, the roof rains 15 and 16, and the rear header 19, and is disposed so as to cover the passenger compartment inner side of the roof panel. The top ceiling 17 is fixed to the front header 13, the roof rains 15 and 16, and the rear header 19 by a plurality of fixing parts.

[0032] 1, the vehicle 1 further includes at least a pair of clips 21, which are first fastening members that secure the top ceiling 17 to the rear header 19. The pair of clips 21 secure the top ceiling 17 to the rear header 19 at a pair of fixing points 17b spaced apart in the vehicle width direction as shown in FIG.

[0033] The clips 21 may be one pair or multiple pairs, and the present invention does not limit the number of pairs of clips 21. The clips 21 may be configured to be able to fix the top ceiling 17 to the rear header 19, and the present invention does not particularly limit the shape and structure of the clips 21. For example, like the clips 21 in Figures 9 and 10, the clips 21 may be configured to be fixed to the upper surface of the top ceiling 17 and have a head that fits into the through-hole 19a of the rear header 19.

[0034] The displacement of the rear header 19 is greatest at the position of the antinode of the deformation in the vibration mode of the rear header 19 in the frequency range when road noise is generated. The position of the antinode in the rear header 19 and its surrounding area are areas where the displacement is locally large. Research by the inventors has revealed that such an area of ​​large displacement in the rear header 19 exists in an area where there are two positions that are equal in the vehicle width direction dimension to the center line C of the top ceiling 17 and are separated by a distance of 37 to 78% of the vehicle width L1 of the rear end 17a of the top ceiling 17 (see FIG. 2).

[0035] For example, in the case of contour maps showing the degree of deformation in a vibration mode of the rear header 19 as viewed from the rear and above of the vehicle as shown in Figures 4 and 5, the antinode of the deformation in the vibration mode of the rear header 19 is located at position P3 (a position spaced apart by 57% of the above-mentioned range) which has the same vehicle width dimension as the center line C extending in the vehicle longitudinal direction. The darker colored region in Figures 4 and 5, which indicates a large degree of displacement, exists in a range including the two positions P3 and corresponding to two positions spaced apart by 37 to 78% of the width L1 of the rear end 17a (see Figure 2).

[0036] In Figures 4 and 5, the two positions P1 correspond to the comparative example of a conventional structure, which will be described later. Because they are spaced apart by 47% of the distance within the above-mentioned range, they are close to the antinode position P3, and therefore the degree of displacement of the rear header 19 is large (the darker areas in Figures 4 and 5). On the other hand, at positions sufficiently far from the two antinode positions P3, such as two positions P2 (29% positions) that are sufficiently inside the two antinode positions P3 or two positions P4 (95% positions, i.e., positions close to both ends of the top ceiling 17), the degree of displacement is smaller than that of the antinode position P3. This is evident from the fact that positions P2 and P4 in Figures 4 and 5 are in areas that are clearly lighter in color than antinode position P3 and position P1 in the comparative example. Furthermore, the degree of displacement is smallest at the center line C of the rear header 19 (the white area in Figures 4 and 5).

[0037] Looking at Figures 4 and 5 above, it can be seen that vibration of the top ceiling 17 can be suppressed by placing a pair of clips 21 at or near node positions (specifically, both ends and the middle position of the rear header 19) while avoiding the antinode positions and their surrounding areas of the deformation in the vibration mode of the rear header 19.

[0038] Therefore, in this embodiment, in order to suppress vibration of the top ceiling 17, the pair of fixing points 17b shown in Figure 2, which are used to fix the top ceiling 17 to the rear header 19 using the pair of clips 21, are set at or near the node position, avoiding the above-mentioned antinode position and its surroundings.

[0039] 2 are set at positions where their vehicle width dimensions are equal to the center line C extending in the vehicle front-rear direction at the vehicle widthwise middle position of the top ceiling 17, and where the distance L2 between the pair of clips 21 is 35% or less or 80% or more of the vehicle width L1 of the rear end 17a of the top ceiling 17 (i.e., a distance of 0 to 35% or 80 to 100%). By setting the positions of the pair of fixing points 17b in this way, it becomes possible to suppress vibration of the top ceiling 17.

[0040] This vibration suppression effect is clear from the graph shown in Fig. 3. Fig. 3 is a graph showing the relationship between the ratio of the length L2 between the pair of clips 21 to the overall width L1 of the rear end 17a in the vehicle longitudinal direction of the top ceiling 17 shown in Fig. 2, and the difference in equivalent radiated power (ERP) from a comparative example having a conventional structure. Specifically, the comparative example here is a case where a pair of clips 21 is arranged at two positions P1 (positions spaced apart by 47% of the distance in the above-mentioned range) shown in Figs. 4 and 5.

[0041] As shown in Figure 3, in the region R1 (0-35%) where the ratio (L2 / L1) of the length L2 between the pair of clips 21 to the overall width L1 of the rear end 17a of the top ceiling 17 in the vehicle longitudinal direction is 35% or less, and in the region R2 (80-100%) where it is 80% or more, a vibration damping effect of 2 dB or more can be reliably obtained in terms of the difference in equivalent radiated power (ERP) from the comparative example. On the other hand, as shown in Figure 3, in the region of 37-78%, since the fixed point 17b is close to the antinode position of the vibration mode of the rear header 19, the degree of displacement is large, and therefore only a vibration damping effect of 2 dB or less can be obtained.

[0042] Preferably, if the pair of fixing points 17b are positioned such that the distance L2 between the pair of clips 21 is 30% or less or 90% or more of the width L1 in the vehicle width direction of the rear end 17a of the top ceiling 17, it can be seen that a vibration damping effect of 3dB or more can be obtained in terms of the difference in equivalent radiated power (ERP) from the comparative example.

[0043] Therefore, in order to position a pair of fixed points 17b in the region R1 (0 to 35%) and the region R2 (80 to 100%) of 80% or more shown in Figure 3, the pair of fixed points 17b can be positioned at a position that is significantly shifted inward or outward from the position P1 of the pair of fixed points in the comparative example of the conventional structure, as shown in Figures 6 to 8.

[0044] For example, in the example shown in Fig. 6, the pair of fixing points 17b are positioned at a position sufficiently further inward than the position P1 of the pair of fixing points in the comparative example (a position where the above L2 / L1 is 35% or less). In the example shown in Fig. 7, the pair of fixing points 17b are positioned at a position aligned with the center line C at the middle position in the width direction of the top ceiling 17 (a position where the ratio is 0%). In the example shown in Fig. 8, the pair of fixing points 17b are positioned at a position sufficiently further outward than the position P1 of the pair of fixing points in the comparative example (a position where the ratio is 80% or more).

[0045] The arrangement of the pair of fixing points 17b shown in Figures 6 to 8, which are the fixing points of a pair of clips 21, is sufficient as long as there is at least one pair of fixing points 17b, and may be an arrangement of two or more pairs of fixing points 17b combining the arrangements of the pairs of fixing points 17b shown in Figures 6 to 8.

[0046] Here, as shown in FIG. 8, in addition to the pair of fixing points 17b formed by the pair of clips 21 (first fastening members), a second fastening member may be further provided that fixes the top ceiling 17 to the rear header 19 at fixing point 17c at the middle position of the top ceiling 17 in the vehicle width direction (a position on center line C). The second fastening member may have the same shape and configuration as the clip 21. In this case, as shown in FIG. 8, the top ceiling 17 can be more stably fixed to the rear header 19 while suppressing vibration of the top ceiling 17 at the pair of fixing points 17b formed by the pair of clips 21 and at fixing point 17c formed by the second fastening member at or near a node position that avoids the antinode position and its surroundings of the vibration mode of the rear header 19.

[0047] Furthermore, when a pair of clips 21 are positioned at the middle position of the top ceiling 17 in the vehicle width direction, as in the pair of fixing points 17b shown in Figure 7, they are positioned at the deformation node position in the vibration mode of the rear header 19, thereby further suppressing the transmission of vibration energy to the top ceiling 17.

[0048] Moreover, like the pair of fixing points 17b shown in Figure 7, it is preferable that the pair of clips 21 are arranged side by side in the fore-and-aft direction of the vehicle at a midpoint in the vehicle width direction for reasons of convenience of placement, mounting strength, or other reasons.

[0049] Here, in a configuration in which a pair of clips 21 are positioned at the midpoint of the top ceiling 17 in the vehicle width direction, as in the pair of fixing points 17b shown in Figure 7 (specifically, positioned side by side in the fore-and-aft direction of the vehicle at the midpoint of the vehicle width direction), when fixing the top ceiling 17 to the rear header 19 with the pair of clips 21, it is difficult to align the pair of clips 21 in the vehicle width direction with the rear header 19, and it is difficult to maintain the assembly accuracy of the top ceiling 17.

[0050] Therefore, a manufacturing method suitable for the upper structure of the vehicle 1 shown in FIG. 7 may be carried out in the following order of a preparation step, a temporary fixing step, and a final fixing step, as shown in FIGS.

[0051] First, as shown in Fig. 9, in a preparation step, a pair of clips 21 are fixed to the middle position 17e of the top ceiling 17 in the vehicle width direction, specifically, fixed side by side in the fore-and-aft direction of the vehicle like the pair of fixing points 17b in Fig. 8. At the same time, a pair of temporary fixing members 22 are fixed to both end portions 17d, 17d of the top ceiling 17 in the vehicle width direction.

[0052] 9, in the temporary fixing process, a pair of temporary fixing members 22 are temporarily and detachably fixed to the rear header 19, thereby temporarily fixing both ends 17d, 17d of the top ceiling 17 in the vehicle width direction to the rear header 19. For example, the bulging heads 22a of the temporary fixing members 22 are fitted into the through holes 19b at both ends of the rear header 19 in the vehicle width direction. In this way, by temporarily fixing both ends 17d, 17d of the top ceiling 17 in the vehicle width direction to the rear header 19 with the pair of temporary fixing members 22, the posture of the top ceiling 17 before being permanently fixed by the clips 21 is stabilized.

[0053] Therefore, even if there are various work processes for assembling the vehicle before the main fixing process, the top ceiling 17 is supported at both ends in advance by the pair of temporary fixing members 22 in the temporary fixing process, which prevents displacement or deformation of the top ceiling 17. Note that the work processes also include a waiting process.

[0054] After the above-described work steps, in the main fixing step, the pair of clips 21 are fixed to the rear header 19 and the pair of temporary fastening members 22 are removed from the rear header 19, thereby fixing the top sealing 17 to the rear header 19 at the vehicle width direction intermediate position 17e with the pair of clips 21. For example, while removing the head 22a of the temporary fastening member 22 from the through hole 19b of the rear header 19, the bulged head 21a of the clip 21 is fitted into the through hole 19a at the vehicle width direction intermediate portion of the rear header 19.

[0055] By manufacturing the above-mentioned upper structure using this procedure, it is possible to accurately and reliably fix the top sealing 17 at the vehicle widthwise intermediate position 17e, which is the deformation node position of the rear header 19, using a pair of clips 21.

[0056] A more preferred manufacturing method is as shown in Figures 9 and 10, in which the top sealing 17 is displaceable between two forms, namely the first form shown in Figure 9 and the second form shown in Figure 10, and has a selective shape retention function that selectively retains either one of the first form or the second form, so that the pair of temporary fastening members 22 can be automatically detached in this fixing process.

[0057] Specifically, in the above preparation process, a top sealing 17 is prepared in which the portion 17f between both ends 17d, 17d of the top sealing 17 in the vehicle width direction is elastically deformed in the vertical direction, so that the top sealing 17 can be displaced between a first shape shown in Figure 9, which is curved downward, and a second shape shown in Figure 10, which is curved upward, and which has an alternative shape retention function that selectively retains either the first shape shown in Figure 9 or the second shape shown in Figure 10.

[0058] In other words, this top ceiling 17 has a configuration that allows it to transition from a first form shown in Figure 9, in which both end portions 17d, 17d in the vehicle width direction are at a predetermined upper position and the intermediate position 17e in the vehicle width direction is at a predetermined lower position, to a second form shown in Figure 10, in which both end portions 17d, 17d in the vehicle width direction are displaced from a predetermined upper position to a predetermined lower position and the intermediate position 17e in the vehicle width direction is displaced from a predetermined lower position to a predetermined upper position.

[0059] The top sealing 17 having the above-described alternative shape-retaining function is composed of, for example, a curved leaf spring and two sheets of nonwoven fabric or other material attached to both sides of the leaf spring under tension. The leaf spring only needs to be slightly curved to allow the temporary fastening member 22 to be released during the main fixing process, as shown in Figure 10.

[0060] In a manufacturing method using a top sealing 17 having such a configuration, in the above-mentioned temporary fastening process, a pair of temporary fastening members 22 fixed to both ends 17d, 17d of the top sealing 17 in the vehicle width direction are temporarily fastened to the rear header 19 in a detachable manner, with the top sealing 17 in the first form shown in Figure 9.

[0061] Then, in the above-described main fixing process, the pair of clips 21 fixed to the vehicle width direction intermediate position 17e of the top ceiling 17 are fixed to the rear header 19, and the portion 17f between both vehicle width direction ends 17d, 17d of the top ceiling 17 is elastically deformed to transition from the first configuration shown in Fig. 9 to the second configuration shown in Fig. 10, thereby lowering both vehicle width direction ends 17d, 17d and releasing the pair of temporary fastening members 22 from the rear header 19. This makes it possible to fix the pair of clips 21 at the vehicle width direction intermediate position 17e to the rear header 19 accurately and reliably.

[0062] (Features of this embodiment) (1) The upper structure of the vehicle 1 of this embodiment includes a pair of clips 21 as at least a pair of first fastening members that secure the top ceiling 17 to the rear header 19. As shown in Fig. 2, the pair of clips 21 secure the top ceiling 17 to the rear header 19 at a pair of fixing points 17b that are located at positions that have equal vehicle width dimensions with respect to the center line C of the top ceiling in the vehicle width direction.

[0063] The pair of clips 21 are positioned at the middle of the top ceiling 17 in the vehicle width direction, with equal vehicle width dimensions relative to the center line C extending in the fore-and-aft direction of the vehicle, and the top ceiling 17 is fixed to the rear header 19 at a position where the distance L2 between the pair of clips 21 is 35% or less or 80% or more of the vehicle width L1 of the rear end 17a of the top ceiling 17 (a position where the distance L2 is within the range of region R1 or region R2 in Figure 3), for example, at the position of a pair of fixing points 17b shown in Figures 6 to 8.

[0064] This allows the top ceiling 17 to be fixed by the clip 21 at or near the position of the deformation node in the vibration mode of the rear header 19 in the frequency range when road noise is generated, i.e., the position where displacement is minimum (theoretically, displacement is zero). This makes it possible to suppress the transmission of vibration energy to the top ceiling 17, thereby suppressing the transmission of road noise that is unpleasant to occupants of the vehicle 1. This achieves a vibration reduction effect of 2 dB or more in the top ceiling 17. This 2 dB is the minimum level at which occupants can perceive the vibration reduction effect. As a result, it becomes possible to reduce the vibration energy transmitted to the top ceiling 17 without weakening the rigidity of the top ceiling 17.

[0065] (2) In the upper structure of the vehicle 1 of this embodiment, it is preferable that the pair of clips 21 fix the top ceiling 17 to the rear header 19 at a pair of fixing points 17b where the distance L2 between the pair of clips 21 is 30% or less or 90% or more of the width of the rear end 17a of the top ceiling 17 in the vehicle width direction.

[0066] This configuration further suppresses the propagation of vibration energy to the top ceiling 17, thereby further suppressing the transmission of road noise that is unpleasant to the occupants of the vehicle 1. Specifically, the top ceiling 17 can achieve a vibration reduction effect of 3 dB or more.

[0067] (3) In addition, the upper structure of the vehicle 1 of this embodiment may further include, in addition to the pair of clips 21 which are the first fastening members described above, a second fastening member which fixes the top ceiling 17 to the rear header 19 at a fixing point 17c at the middle position of the top ceiling 17 in the vehicle width direction, as shown in Figure 8.

[0068] The middle position of the top ceiling 17 in the vehicle width direction is the position of the deformation node in the vibration mode of the rear header 19, so in addition to fixing it with a pair of clips 21 at the above-mentioned pair of fixing points 17b, by further fixing the top ceiling 17 to the rear header 19 at fixing point 17c, which is the middle position in the vehicle width direction, with a second fastening member, it is possible to fix the top ceiling 17 even more stably with the pair of clips 21 and the second fastening member while suppressing the vibration of the top ceiling 17.

[0069] (4) In the upper structure of the vehicle 1 of this embodiment, a pair of clips 21 may be arranged at the middle position in the vehicle width direction of the top ceiling 17 (specifically, arranged side by side in the fore-and-aft direction of the vehicle at the middle position in the vehicle width direction), as in the pair of fixing points 17b shown in Figure 7.

[0070] In this configuration, each of the pair of clips 21 is positioned at a vehicle widthwise intermediate position of the top ceiling 17, which is the position of a deformation node in the vibration mode of the rear header 19. In other words, the distance L2 between the pair of clips 21 in the vehicle width direction is 0, and the ratio of the distance L2 to the width L1 of the rear end 17a of the top ceiling 17 is 0%. By positioning the pair of clips 21 at such a vehicle widthwise intermediate position, it is possible to further suppress the transmission of vibration energy to the top ceiling 17 and further suppress the transmission of road noise that is unpleasant to the occupants of the vehicle 1. Furthermore, the pair of clips 21 aligned in the vehicle fore-and-aft direction can maintain a strong fixation of the top ceiling 17.

[0071] (5) In a configuration in which a pair of clips 21 are arranged at the midpoint of the top ceiling 17 in the vehicle width direction, as shown in Figure 7 at a pair of fixing points 17b (specifically, arranged side by side in the fore-and-aft direction of the vehicle at the midpoint of the vehicle width direction), when fixing the top ceiling 17 to the rear header 19 with the pair of clips 21, it is difficult to align the pair of clips 21 in the vehicle width direction with the rear header 19, and it is difficult to maintain the assembly accuracy of the top ceiling 17.

[0072] Therefore, a manufacturing method suitable for the upper structure of the vehicle 1 shown in FIG. 7 may be carried out in the following order of a preparation step, a temporary fixing step, and a final fixing step, as shown in FIGS.

[0073] That is, as shown in Figure 9, the manufacturing method of this embodiment is characterized by including: (i) a preparation process of fixing a pair of clips 21 to the vehicle width intermediate position 17e of the top sealing 17 (specifically, fixing them side by side in the fore-and-aft direction of the vehicle) and fixing a pair of temporary fastening members 22 to both vehicle width end portions 17d, 17d; (ii) a temporary fastening process of temporarily fastening both vehicle width end portions 17d, 17d of the top sealing 17 to the rear header 19 by temporarily fastening the pair of temporary fastening members 22 to the rear header 19; (iii) a work process of assembling the vehicle 1 after the temporary fastening process; and (iv) a final fastening process of fixing the top sealing 17 to the rear header 19 at the vehicle width intermediate position 17e with the pair of clips 21 after the work process by fixing the pair of clips 21 to the rear header 19 and detaching the pair of temporary fastening members 22 from the rear header 19.

[0074] In this manufacturing method, in a preparation step, a pair of clips 21 are fixed at a vehicle widthwise intermediate position 17e (specifically, fixed side by side in the vehicle front-rear direction), and a pair of temporary fastening members 22 are fixed to both vehicle widthwise end portions 17d, 17d. Then, before the top sealing 17 is permanently fixed to the rear header 19 by the pair of clips 21, in a temporary fastening step, the pair of temporary fastening members 22 are temporarily fastened to the rear header 19 in advance, thereby temporarily fastening both vehicle widthwise end portions of the top sealing 17 to the rear header 19 in advance. This makes it possible to maintain assembly accuracy when assembling the top sealing 17 in the subsequent permanent fastening step.

[0075] Therefore, even if there are various work processes for assembling the vehicle before the main fixing process, the top ceiling 17 is supported at both ends by the pair of temporary fixing members 22, which prevents the top ceiling 17 from shifting or deforming. Note that the work processes also include a waiting process.

[0076] Then, after the temporary fastening with the pair of temporary fastening members 22, in the main fastening process, the pair of clips 21 are fixed to the rear header 19 and the pair of temporary fastening members 22 are released from the rear header 19, thereby fixing the top ceiling 17 to the rear header 19 with the pair of clips 21 aligned in the fore-and-aft direction of the vehicle at the vehicle widthwise intermediate position 17e. This makes it possible to accurately and reliably fix the top ceiling 17 to the vehicle widthwise intermediate position 17e, which is the position of the deformation node of the rear header 19, with the pair of clips 21.

[0077] (6) Furthermore, in a preferred manufacturing method for the upper structure of the vehicle 1, in the above-mentioned preparation step, a top sealing 17 is prepared in which a portion 17f between both vehicle width direction ends 17d, 17d of the top sealing 17 is elastically deformed in the vertical direction, thereby being capable of displacing between a first configuration curved downward as shown in Fig. 9 and a second configuration curved upward as shown in Fig. 10, and which has a selective shape retention function of selectively retaining either the first configuration shown in Fig. 9 or the second configuration shown in Fig. 10. In the temporary fixing step, a pair of temporary fixing members 22 fixed to both vehicle width direction ends 17d, 17d of the top sealing 17 can be temporarily fixed to the rear header 19 when the top sealing 17 is in the first configuration shown in Fig. 9. In this fixing process, a pair of clips 21 fixed to the vehicle width intermediate position 17e of the top ceiling 17 are fixed to the rear header 19, and the portion 17f between the vehicle width end portions 17d, 17d of the top ceiling 17 is elastically deformed to transition from the first form shown in Figure 9 to the second form shown in Figure 10, thereby lowering the vehicle width end portions 17d, 17d and detaching the pair of temporary fastening members 22 from the rear header 19.

[0078] In this feature, the pair of clips 21 and the pair of temporary fastening members 22 are connected by the elastically deformable top ceiling 17 as described above, so that when the pair of clips 21 located at the vehicle width direction intermediate position 17e of the top ceiling 17 are fastened to the rear header 19 in the main fastening process, the top ceiling 17 is elastically deformed to transition from the first configuration shown in Fig. 9 to the second configuration shown in Fig. 10, thereby lowering both vehicle width direction end portions 17d, 17d of the top ceiling 17, and accordingly, the pair of temporary fastening members 22 can be automatically detached from the rear header 19. Therefore, in the main fastening process, the pair of temporary fastening members 22 can be automatically detached simply by fastening the pair of clips 21, which facilitates the installation work of the top ceiling 17. [Explanation of symbols]

[0079] 1 vehicle 13 Front Header 17 Top ceiling 17a rear end 17b: fixing point of clip 21 (first fastening member) 17c Fixation point of second fastening member 19 Rear header 21 Clip (first fastening member) P1 Fixed point of conventional structure as a comparison example P2 A point slightly inside P1 P3 Position of the antinode of vibration mode of rear header 19 P4 Vibration mode node positions at both ends of rear header 19

Claims

1. Roof panel and a rear header extending in the vehicle width direction and fixed to a rear end portion of the roof panel; a top ceiling disposed on a vehicle interior side relative to the rear header and covering the roof panel from the vehicle interior side; at least one pair of first fastening members that fasten the top sealing to the rear header; Equipped with The pair of first fastening members are positioned at a vehicle width direction intermediate position of the top ceiling, and have equal vehicle width dimensions with respect to a center line extending in the vehicle front-rear direction, and the distance between the pair of first fastening members is 35% or less or 80% or more of the vehicle width direction width of the rear end of the top ceiling, and the top ceiling is fixed to the rear header at a position. characterized in that Vehicle superstructure.

2. The vehicle upper structure according to claim 1, The pair of first fastening members fasten the top ceiling to the rear header at a position where the distance between the pair of first fastening members is 30% or less or 90% or more of the width of the rear end of the top ceiling in the vehicle width direction. Vehicle superstructure.

3. The vehicle upper structure according to claim 1 or 2, a second fastening member for fastening the top sealing to the rear header at a middle position of the top sealing in the vehicle width direction; Vehicle superstructure.

4. The vehicle upper structure according to claim 2, The pair of first fastening members are arranged at a middle position in the vehicle width direction of the top ceiling. Vehicle superstructure.

5. 5. The method for manufacturing a vehicle upper structure according to claim 4, a preparation step of fixing the pair of first fastening members to a vehicle width direction intermediate position of the top ceiling and fixing a pair of temporary fastening members to both ends in the vehicle width direction; a temporary fixing process of temporarily fixing both ends of the top sealing in the vehicle width direction to the rear header by temporarily fixing the pair of temporary fixing members to the rear header; a work process of assembling the vehicle after the temporary fixing process; a main fixing process in which, after the working process, the pair of fastening members are fixed to the rear header and the pair of temporary fastening members are detached from the rear header, thereby fixing the top sealing to the rear header at a vehicle width direction intermediate position by the pair of fastening members; characterized in that it comprises A method for manufacturing a vehicle superstructure.

6. 6. The method for manufacturing a vehicle upper structure according to claim 5, In the preparation step, a top ceiling is prepared which is capable of being displaced between a first shape curved downward and a second shape curved upward by elastically deforming a portion of the top ceiling between both ends in the vehicle width direction in the vertical direction, and which has an alternative shape retention function of alternatively retaining either the first shape or the second shape; In the temporary fixing step, the pair of temporary fixing members fixed to both ends of the top sealing in the vehicle width direction in the first configuration are temporarily fixed to the rear header, In the main fixing step, the pair of first fastening members fixed to the vehicle width direction intermediate position of the top ceiling are fixed to the rear header, and a portion of the top ceiling between both end portions in the vehicle width direction is elastically deformed to transition from the first configuration to the second configuration, thereby lowering both end portions in the vehicle width direction and releasing the pair of temporary fastening members from the rear header. A method for manufacturing a vehicle superstructure.

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